LOAD CELL SYSTEM

FAULT FINDING GUIDE

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1.

BASIC CHECKS

This first chapter is intended to aid in fault finding in load cell systems using Wheatstone bridge type
load cells. The items covered are designed to assist in checking connection of the load cell and
obtaining a display from a load cell monitor. Since only a load cell and monitor are being checked the
main purpose is to isolate whether any problems seen arise from the load cell or the monitor.
For other load cell system requirements such as alarm setting and retransmission outputs consult
the instruction manual of the load cell monitor being used.
Equipment required: A multimeter capable of measuring Ohms, Volts and mV. To test the
monitor independently a load cell simulator will be required.
1.1

Basic load cell system

The basic load cell system consists of a 4 wire load cell connected to a load cell monitor. The
monitor supplies a voltage called the excitation voltage to the load cell and the load cell returns a
millivolt (mV) signal back to the monitor. The mV signal changes with the load experienced by the
load cell and this mV signal is used to determine the display value on the monitor.

1.2

Basic load cell resistance checks

Unfortunately there is no standard wiring colour code for load cells so you will need to know from
data supplied with the cell which wires are the excitation wires and which wires are the signal wires
(see section 2.6 for colour code examples). If you do not have this information then as shown in
the diagram above in addition to the 4 resistance elements which make up the Wheatstone bridge
there are commonly one or two resistors in the excitation lines. This means that the resistance
across the excitation wires is usually the highest resistance measured across any two wires. The
resistances also vary between manufacturers and load cell types, input and output resistance values
are often provided in the data supplied with the load cell.

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To test the cell obtain a meter capable of measuring Ohms, measure across each pair of wires in
turn and record the results (space provided in the table which follows). The load cell must be
completely disconnected from the monitor and at no load when these tests are made.
The table which follows gives measurements taken with a sample 350 load cell with one resistor in
its Ex+ line i.e. these readings show lowest values between signal lines and Ex-. For a load cell
with two resistors in its excitation lines (one in Ex+ and one in Ex-) you would expect the Ex+ and
Ex- to S+ and S- measured values to be roughly the same. In a typical load cell the S+ to S- should
be close to the specified output resistance of the cell i.e. within one or two Ohms, other values are
nominal.
Resistance check

Typical 350

Ex+ to Ex -

410 approx

S+ to S-

350 approx

Ex + to S+

315 approx

Ex+ to S-

315 approx

Ex- to S+

280 approx

Ex- to S-

280 approx

Record your readings

Record your readings

Record your readings

If the resistance readings appear to be correct move on to section 1.3. If the resistance
readings appear to be incorrect e.g. outside expected range, open circuit or short circuit across any
two wires then the likely cause is a damaged or faulty load cell or incorrect/faulty wiring.

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1.3

Checks when load cell is connected to monitor

When installing a load cell system the usual installation procedure would be:
1. Install load cell in position
2. Connect excitation and signal wires to monitor
3. Calibrate monitor to read the load in the units required e.g. kg or Tonnes (consult monitor
instruction manual for calibration procedures
4. Check monitor is reading correctly over a range of values
If you wish to check the system prior to installation or if the load cell will not calibrate or the monitor
can not be made to read correctly or is giving unstable readings make the following
measurements.
1. Using a voltmeter measure and record the excitation voltage
2. Using a mV meter measure and record the signal voltage at the lowest load you can apply
3. Using a mV meter measure and record the signal voltage at a load as close to the rating of
the load cell as possible
4. Obtain the mV/V output figure from the load cell data supplied with the load cell and
compare the signal changes seen with the theoretical values from the load cell data.
1.4

Other common system problems

Some common problems which may cause difficulty when installing a system:
1. Incorrect wiring of load cell to monitor - i.e. signal & excitation wires crossed at one or
---more points. In AIC monitors this is likely to show an error message of or or on the
display.
2. Friction or restriction of load cell movement - If the load cell is prevented from moving
freely due to friction or is prevented from moving to its full deflection due to an obstacle the
output from the load cell will not be correct. Typical display reading indications are that the
display is slow to respond to load changes and/or that the display does not always return to
zero when expected and/or that the display is not linear. Check that there are no
obstructions to free movement and that the load cell is mounted correctly.
3. Over stressed load cell - If the load cell becomes over stressed sufficiently it will take
on a permanent deformation. This will lead to a high offset voltage which may make it
impossible to calibrate successfully and may also lead to non linearity over its operating
range.
4. Moisture in the load cell or wiring - if moisture is allowed to enter the electrical circuit of the
load cell or wiring the display reading will change due to current flowing through both the load
cell bridge and the new current paths created by moisture. Ensure that cells of the correct
environmental protection (IP) rating are used for the application and that moisture cannot
enter the cable through cuts, cable joins and exposed cables.
5. High resistance cable joins - When a load cell cable is extended it is important that the joins
made are electrically sound and free from moisture. A damp or corroded join will lead to
unreliable readings.
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6. Incorrect mounting of the load cell - Load cells are manufactured in many types e.g. shear
beam, "S" type etc. Each type requires a particular form of mounting for correct operation.
Check the load cell type and mounting requirements if in doubt.
7. Electrical damage to load cells - Electrical damage can often occur due to lightning
strikes, welding on the structure to which the load cell is attached and other causes.
Surge suppression devices for load cell systems are available from suppliers such as MTL.
Welding currents will destroy the cell. If welding on the structure is likely and the load cell
is not insulated from the current flow, copper or stainless steel braids should be used to
connect each end of the load cells to ground to help prevent electrical damage.
8. Non linearity of display reading - Friction & restriction as described in 2. above could be the
cause of non linearity. With some load cell designs, particularly those designed for high loads
e.g. Tonnes the output of the cell may be non linear over parts of its measurement range,
typically the low load end of the curve may not be quite linear. Some load cell monitors allow
extra calibration points to correct this non linear output from the cell. It is also worth checking
in instruments with this feature that the linearising functions have been turned off if they
are not required i.e. if it is turned on and the cell output is linear the linearising functions
may make it appear non linear.
1.5

Technical assistance

To save time when seeking assistance, as much as possible of the information below should be
obtained before contacting the monitor or load cell manufacturer for technical assistance.
Photocopy this page and fill in as much information as you can.
Question

Record your answer

Model number of monitor

Model number of load cell
Capacity of load cell
mV/V output of load cell

mV/V

Load cell resistance Ex+ to Ex-

Load cell resistance S+ to S-

Load cell resistance Ex+ to S+

Load cell resistance Ex+ to S-

Load cell resistance Ex- to S+

Load cell resistance Ex- to S-

Excitation voltage measured

mV signal at low load & load value

mV at

load

mV signal at high load & load value

mV at

load

Monitor mV/V input range setting

mV/V

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APPENDIX
2.1

mV/V explained

When a load cell is obtained it is usually accompanied by a certificate which details the
specifications for the load cell including the signal output span per volt of excitation or mV/V output.
Usually the output from a load cell will be approximately 0mV at zero load though typically there may
be a small offset voltage at zero load. Over the full rated capacity of the load cell the mV output will
change. The amount by which it changes depends on the resistance change in the cell and on
the excitation voltage applied. Since the load cell manufacturer does not know what excitation
voltage will be applied to the cell rather than quote the mV output overfull range they will quote the
millivolt output per volt of excitation or in its short form mV/V.
For example a 250kg load cell may be quoted as having a 2.357mV/V output. If the excitation voltage
is 1 0V they you could expect a mV output of 0mV at zero load and 23.57mV at 250kg load. Again
the actual voltages seen could be affected by a usually small offset voltage.
2.2

Load cell types

Shear beam - the shear beam load cell is fixed rigidly at one end with the force being applied
to the other end. These can be used singly or in groups e.g. a platform scale using one cell in
each corner.
Double ended shear beam type cells are of different construction and are fixed rigidly at each
end with the force being applied to the centre of the beam.
Single point load cells are of similar design

Compression - the compression load cell is designed to operate in compression only. Some
designs require load to be applied at one end only, other designs can be compressed by force
at both ends.

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S type - the S type load cell can be used in tension

and compression. The signal voltage output will reverse
in polarity when the force changes from tension to
compression i.e. the display value may change from.
Tension load cells and Load links are designed to
operate under tension only.

Rope clamp - the rope clamp load cell is popular in

hoist and crane applications due to it ease of
installation. The rope passes through the cell and when
tension is applied to the rope due to a weight being
lifted the tension produces a bending force on the cell.
The mounting position of this type of load cell is very
important. Most of these type of cells are mounted at
the dead end of the rope allowing enough rope at each
end for flexing i.e. ensure that the attachment is not so
close to the dead end that the rope is rigid and cannot
flex.
Since these cells are designed to operate over a very
wide range of loads and rope sizes, and because the
rope system often goes through a series of ''drops'', it is
often the case that the mV output from these cells is at
the low end of the range. The sensitivity of the monitor
may need to be increased by lowering the mV range to
compensate.

Load pin - load pin cells are designed to be installed in

the axis of a sheave, shackle etc. through which force
is applied. Most common load pins will measure force
in one direction only. The direction of force is often
marked with an arrow at one end of the pin or
instructions for alignment may be given in the load cell
certificate. If the load is off axis, the output will be
reduced. At 90 degrees off axis the output will not
change with a change in load.

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2.3

Six wire load cells

Six wire load cells use two extra wires known as sense or reference wires. These sense wires connect
to the excitation wires at the load cell as shown below. Monitors which will accept 6 wire load cells
measure the current passing down the Ex+ to SEN+ and Ex- to SEN- wires. This measurement
allows the monitor to compensate for any resistance changes in the wiring to the load cell due to
changes in temperature.
As can be seen below the sense wiring can be tested using an Ohm meter. The resistance between
Ex+ & SEN+ and Ex- & SEN- should be no more than a few Ohms.

2.4

Single & multi-point weighing

Single point weighing - single point type load cells can be used with single load cell platform
designs, usually in fairly low capacity systems. S type, tension type, rope clamp & load pins load
cells are also used in single point systems.
Two point weighing - can be used for longer thin platforms, beams and girders e.g. load cell
near each end.
Three point weighing - often used in weighing vertical cylinders. Using 3 points gives
less complicated leveling than when more load cells are used.
Four point weighing -typically used with high capacity platform scales and rectangular containers
More than 4 points -typically used in very high capacity and/or very large container/platform
measurement systems
Using pivots and load cells - savings in load cell costs are often made by using pivots e.g. instead
of using two load cells the load on a beam can be measured by using a load cell at one end and a pivot
on the other. The use of a pivot is not recommended unless accuracy is not important. If a pivot is
used instead of an extra cell it must be taken into account that the mechanical design must allow
adequate and linear transference of load to the load cells in the system. Any friction in the pivot will
result in slow response, inaccurate and non repeatable measurements

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